Deconstructed carpet and method of manufacture

ABSTRACT

A deconstructed tufted carpet having an at least partially visible primary backing. In aspects, deconstructed carpet can utilize the primary backing layer as a design element of the overall pattern and styling in order to reduce material use, waste and the ounce weight of the finished carpet and to improve the method of carpet construction. In order to expose the primary backing, at least some yarn can be pulled very low in the pattern areas to expose the primary backing layer. It is contemplated that the primary backing layer can have a color that comprises part of the overall pattern and styling of the carpet.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Divisional of U.S. application Ser. No. 14/216,593filed Mar. 17, 2014, which claims priority to U.S. ProvisionalApplication No. 61/794,873, filed Mar. 15, 2013, which is herebyincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

Aspects described herein relate generally to carpet designs having an atleast partially exposed primary backing layer incorporated into thecarpet design and methods for manufacturing the same.

BACKGROUND OF THE INVENTION

As illustrated in FIG. 1, tufted carpets generally are compositestructures which include yarn (which is also known as a fiber bundle), aprimary backing material having a face surface and a back surface, anadhesive backing material and, optionally, a secondary backing material.To form the face surface of tufted carpet, yarn can be tufted throughthe primary backing material such that the longer length of each stitchextends through the face surface of the primary backing material.Typically, the primary backing material can be made of a woven ornon-woven material such as a thermoplastic polymer, most commonlypolypropylene.

The face of a tufted carpet can generally be made in three ways. First,for loop pile carpet, the yarn loops formed in the tufting process canbe left intact. Second, for cut pile carpet, the yarn loops can be cut,either during tufting or after, to produce a pile of single yarn endsinstead of loops. Third, some carpet styles can include both loop andcut pile. One variety of this hybrid is referred to as tip-shearedcarpet where loops of differing lengths can be tufted followed byshearing the carpet at a height so as to produce a mix of uncut,partially cut, and completely cut loops. Alternatively, the tuftingmachine can be configured so as to cut only some of the loops, therebyleaving a pattern of cut and uncut loops. Whether loop, cut, or ahybrid, the yarn on the back side of the primary backing material cancomprise tight, unextended loops.

The combination of tufted yarn and a primary backing material withoutthe application of an adhesive backing material or secondary backingmaterial is referred to in the carpet industry as raw tufted carpet orgreige goods. Greige goods can become finished tufted carpet with theapplication of an adhesive backing material and an optional secondarybacking material to the back side of the primary backing material.Finished tufted carpet can be prepared as broad-loomed carpet in rollstypically 6 or 12 feet wide. Alternatively, carpet can be prepared ascarpet tiles in varying shapes and sizes.

A substantial demand exists for tufted carpet designs and methods ofmanufacture that reduce the waste produced over conventional tuftedcarpet manufacturing methods that makes more efficient use of materialsand that results in a lighter weight carpet.

SUMMARY

It is to be understood that this summary is not an extensive overview ofthe disclosure. This summary is exemplary and not restrictive, and it isintended to neither identify key or critical elements of the disclosurenor delineate the scope thereof. The sole purpose of this summary is toexplain and exemplify certain concepts of the disclosure as anintroduction to the following complete and extensive detaileddescription.

The present invention is generally directed to a deconstructed tuftedcarpet in which at least a portion of the primary backing is visible orat least partially visible. In aspects, deconstructed carpet can utilizethe primary backing layer as a design element of the overall pattern andstyling in order to reduce material use, waste and the ounce weight ofthe finished carpet and to improve the method of carpet construction. Inone embodiment, in order to expose the primary backing, at least someyarn is pulled very low in the desired exposed member pattern areasthereby exposing a desired amount of the primary backing layer. It iscontemplated that the primary backing layer can have a color thatcomprises part of the overall pattern and styling of the carpet.

Additional features and advantages of exemplary aspects of thedisclosure will be set forth in the description which follows, and inpart will be obvious from the description, or may be learned by thepractice of such exemplary aspects. The features and advantages of suchaspects may be realized and obtained by means of the instruments andcombinations particularly pointed out in the appended claims. These andother features will become more fully apparent from the followingdescription and appended claims, or may be learned by the practice ofsuch exemplary aspects as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several aspects described belowand together with the description, serve to explain the principles ofthe invention. Like numbers represent the same elements throughout thefigures. The patent or application file contains at least one drawingexecuted in color. Copies of this patent or patent applicationpublication with color drawing(s) will be provided by the Office uponrequest and the payment of the necessary fee.

FIG. 1 illustrates one aspect of a deconstructed carpet;

FIG. 2 shows an enlarged plan view of the deconstructed carpet of FIG.1.

FIG. 3 shows an enlarged plan view of the deconstructed carpet of FIG.2.

DETAILED DESCRIPTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawing, and claims, and theirprevious and following description. However, before the present devices,systems, and/or methods are disclosed and described, it is to beunderstood that this invention is not limited to the specific devices,systems, and/or methods disclosed unless otherwise specified, as suchcan, of course, vary. It is also to be understood that the terminologyused herein is for the purpose of describing particular aspects only andis not intended to be limiting.

The following description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present invention are possibleand can even be desirable in certain circumstances and are a part of thepresent invention. Thus, the following description is provided asillustrative of the principles of the present invention and not inlimitation thereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “a needle bar” can include two or more suchneedle bars unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

As used throughout, the term “carpet tile” refers to carpet tiles andother conventional textile-face modular flooring tiles.

As used herein, the definition of the term “color” is referenced interms of the CIELAB color scale, which was created by the InternationalCommission on Illumination (CIE). The CIELAB color scale provides auniform scale for measuring and comparing the color values of differentsamples. Three different color measurements are used to determine theCIELAB color value of a given sample: 1) a white-black colormeasurement; 2) a red-green color measurement; and 3) a yellow-bluecolor measurement. The white-black color measurement represents theamount of white present in the sample relative to the amount of blackpresent in the sample. The red-green color measurement represents theamount of red present in the sample relative to the amount of greenpresent in the sample. The yellow-blue color measurement represents theamount of yellow present in the sample relative to the amount of bluepresent in the sample. CIELAB color scale values can be obtained usingcolor measurement instruments known in the art, including, for example,HunterLab color measurement instruments.

As used throughout, the terms “tuft”, “tufting”, “tufted”, “tufted-in”,and other verb tenses thereof refer to inserting, pressing, passing,and/or any other conventional process by which yarn is attached orotherwise coupled to the carpet backing.

In one aspect, and as shown in FIG. 1, a carpet tile 11 is providedhaving first and second end edges 14 a, 14 b and first and second sideedges 16 a, 16 b. In this aspect, it is contemplated that the distancebetween the first and second end edges 14 a, 14 b of the carpet tile 11can correspond to a length 18 of the carpet tile. It is furthercontemplated that the distance between the first and second side edges16 a, 16 b of the carpet tile 11 can correspond to a width 19 of thecarpet tile.

Referring now to the drawings, in which identical numbers indicateidentical elements throughout the various views, FIGS. 1-3 illustrate afirst aspect of a tufted carpet 10 having an at least partially visibleprimary backing 12, hereto referred to as deconstructed carpet 10.Conventionally, primary backing is considered only a structural elementof carpet and visible primary backing in carpet is considered to be adefect. However, the present disclosure utilizes the primary backinglayer as a design element of the overall pattern and styling in order toreduce material use, waste and the ounce weight of the finished carpetand to improve the method of carpet construction. In one example, inorder to expose the primary backing 12, at least some yarn can be pulledvery low in the exposed member pattern areas 22 to expose or otherwisemake visible to an external viewer, desired amounts of the primarybacking layer. It is contemplated that the primary backing layer canhave a primary backing color that comprises part of the overall patternand styling of the deconstructed carpet.

In aspects of the present disclosure, the deconstructed carpet can havethe tufting pile heights adjusted over conventional tufted carpet suchthat a previous medium pile height becomes a low pile height and theprevious low pile height becomes very low against the primary backing.It is contemplated that the deconstructed carpet can then be finishedsimilarly to conventional tufted carpet. In light of the presentdisclosure, one skilled in the art will appreciate that lowering of thepile heights can allow for a reduction in tufted weight. Thus, inanother aspect, the ounce weight of the deconstructed carpet can be fromabout 6 to about 25 oz., optionally, from about 8 to about 16 oz., and,more particularly, about 10 oz. in a patterned deconstructed carpet.

The deconstructed carpet shown in FIG. 1 can be formed by a conventionalcarpet tufting machine. For example, conventional tufting machine havinga single bar of needles, two bars of needles, and the like can be used.The deconstructed carpet can be, but does not have to be, manufacturedusing a conventional carpet tufting machine. Among other alternatives,and not meant to be limiting, the deconstructed carpet may be producedon a carpet tufting machine having ¼ gauge needle bars, ⅛ gauge needlebars, and/or 10 gauge needle bars. In one exemplary aspect, the desiredcarpet pattern design (and full and partial repeats thereof, if desired)comprising the one or more tufted portion pattern members 20 and the oneor more exposed pattern members 22 can be formed on the deconstructedcarpet by controlling the height of the yarn tufts and the “thread-up”of the machine, i.e., the arrangement of yarn colors dedicated to theneedles of the tufting machine.

Each needle can be threaded with a dedicated yarn type (e.g., singlecolor, space dyed, barber pole, etc.) and color(s). In one example, thecolor shapes of the tufted portion pattern members are formed on thecolor web by contrast between adjacent yarn colors on a single needlerow and by contrast between the yarn colors on the needle bar or needlebars. Thus, the types and colors of yarn 24 used should be selected toachieve a desired contrast between areas of the desired pattern designof the carpet. For example, at least one color in the one or more tuftedportion pattern members should be used to achieve the desired colorcontrast against the colored primary backing. However, it is optional,but not necessary, to use more than one color to achieve the desiredcolor contrast. For example, the primary backing color should differfrom the color therein the tufted portion pattern members in either oneof, or a combination of, hue, chroma, and/or value. In one exemplaryaspect, the primary backing color differs from the plurality of yarnsthat form the at least one color in the tufted portion pattern members.

Any thread-up of the machine may be used in accordance with thisinvention so long as the resultant web forms a carpet in accord with thedirected color and texture design of the deconstructed carpet. Inaspects, deconstructed carpet allows a singular color yarn to be usedand the exposure of the primary backing creates the desired patterndesign of the carpet by the color contrast between the color of the yarnand the color of the primary backing. It is also contemplated thatmultiple colored yarns can be used; however, one skilled in the art willappreciate that in a deconstructed carpet, multiple colored yarns are nolonger a requirement to provide pattern.

As noted above, the characteristic of the deconstructed carpet 10 can befurther controlled by varying the height of the yarn, controlling thepile height of the deconstructed carpet. The longer the length of yarnthat is pushed through the primary backing, the greater its height inthe finished carpet. In the exemplary deconstructed carpet, at leastsome primary backing can be visible in some portions of the tuftedportion pattern members, and some areas can show substantially onlyprimary backing.

In other aspects, either broadloom carpet or carpet tiles can bemanufactured using the deconstructed carpet. In exemplary aspects, thecarpet tile 11 can be substantially rectangular (having a length 18 anda width 19 that are substantially different). It is also contemplatedthat the carpet tile 11 can be substantially square (having a length 18and a width 20 that are substantially equal). However, it iscontemplated that the carpet tile 11 can have any desired shape,including a desired conventional shape or a desired irregular and/ororganic shape. In further exemplary aspects, it is contemplated that thecarpet tile 11 can have a tufted face, a woven face, or a fusion-bondedface that is formed according to conventional methods. In an additionalexemplary aspect, it is contemplated that at least a portion of the faceof the carpet tile 11 can be printed using conventional methods.

Although several embodiments of the invention have been disclosed in theforegoing specification, it is understood by those skilled in the artthat many modifications and other embodiments of the invention will cometo mind to which the invention pertains, having the benefit of theteaching presented in the foregoing description and associated drawings.It is therefore understood that the invention is not limited to thespecific embodiments disclosed herein, and that many modifications andother embodiments of the invention are intended to be included withinthe scope of the invention. Moreover, although specific terms areemployed herein, they are used only in a generic and descriptive sense,and not for the purposes of limiting the described invention.

What is claimed is:
 1. A method for forming a deconstructed carpet,comprising: providing a primary backing layer having a top surface;tufting at least one color yarn in the primary backing layer to extendupwardly from at least a portion of the top surface of the primarybacking layer to form a tufted portion pattern member having a desiredpile height that obscures the underlying top surface of the primarybacking layer, wherein a portion of the primary backing layer is visibleand forms an exposed pattern member that forms part of an overallpattern and styling of the carpet.
 2. The method of claim 1, wherein thecarpet is a broadloom carpet.
 3. The method of claim 1, wherein thecarpet is a carpet tile.
 4. The method of claim 1, further comprisingtufting the at least one color yarn in the exposed pattern and pullingselected yarns low enough to expose the primary backing layer.
 5. Themethod of claim 1, further comprising selecting a primary backing colorfor the primary backing layer.
 6. The method of claim 5, furthercomprising selecting at least one type or color of yarn to achieve adesired contrast in the overall pattern and styling of the carpet. 7.The method of claim 6, wherein at least one color yarn is selected toachieve the desired color contrast against the primary backing color. 8.The method of claim 5, the primary backing color should differ from thecolor of the at least one colored yarn therein the tufted portionpattern member in either one of, or a combination of, hue, chroma,and/or value.
 9. The method of claim 8, wherein the primary backingcolor differs from color of the at least one color yarn.
 10. The methodof claim 1, wherein the at least one color yarn comprises a plurality ofcolored yarns.
 11. The method of claim 1, further comprising selectivelyvarying the pile height of the tufted yarns over the tufted portionpattern member.